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Hydraulic Gear Pump and Motor Failure

Analysis and Repair Guide

Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762


Hydraulic Gear Pump and Motor Failure
Analysis and Repair Guide

The heart of a hydraulic system is the hydraulic pump. The pump is the component that
receives the mechanical energy supplied by the tractor or engine, and converts it to fluid
energy with the use of the hydraulic oil.

A healthy pump will allow the mower system to perform at its maximum level of effectiveness.
Properly maintaining the hydraulic system by changing the oil and the filters and by preventing
or repairing leaks will provide hundreds of hours of trouble free operation.

The fixed displacement gear pumps utilized by Alamo Industrial are of a proven design and will
easily provide exceptional service for the life of the machine. Failures of the front pump are, in
fact, limited to just a few specific modes such as overheating, over-pressurization, shaft failures,
contamination and cavitation. In most cases, damage to the front pump is a RESULT of a
failure and not the true cause of the failure. Simply replacing the pump without understanding
WHY it failed will only result in additional failures and additional expense.
Proper failure analysis of the front pump is essential to understanding why the pump failed, and
thus determining the true cause of the failure. Knowing the TRUE cause of the failure will
prevent additional failures.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 2 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Thrust Plates
Lip Seal Port End Cover
Shaft End Cover

Mounting Flange
Shaft Bushings

Drive Spline

Drive Gear

Idler Gear

Inlet Port

Bearing

Ring Seal (High Gear Housing


Pressure)

The front mounted gear pump utilizes power from the engine crankshaft to provide rotation of
the pump. A flow of oil is produced by the pump due to this rotation. The amount of flow is
dependent upon the size of the gears in the pump and the speed of the engine. Likewise, as
the pump is rated to produce the optimum flow at the rated speed, usually 1800 to 2000rpm,
the pump is described as a Fixed Displacement Pump.

(Single Pump shown above, Tandem Pump shown below)

Bearing Carrier
Bushings

Pumping
sections

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 3 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Tandem Gear Pumps may be needed when there are multiple functions that require different
flows such as a requirement where tractor hydraulics for boom movement is not available.
Tandem pumps operate the same as single pumps, and incorporate a bearing carrier with a
driven shaft coupler to provide the operation of both pumps simultaneously.

Gear pumps and motors


employ a pressure balanced
thrust plate design. Oil
pressure hydraulically
balances the thrust plates
and squeezes them against
the two gear faces. The
squeeze provides a seal
between the gear face and
the thrust plate surface,
preventing high pressure oil
from slipping back to the low
pressure side of the pump.

Mechanical seals and oil


channel inserts are used
to control the oil and
block it from leaking
between the plate and
adjoining castings.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 4 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
A cross sectional view of the pumping chambers illustrates the flow path of the hydraulic oil
through the gear pump. As the gears counter-rotate, the separating gear teeth create a
vacuum, drawing oil into the inlet. Oil is picked up by each tooth and carried around the
outside of the gear. Oil is NOT drawn through the center. The pockets between the gear teeth
and the housing are referred to as Pumping Chambers. As the gear teeth mesh on the outlet
side, oil is forced out of the pockets and exits the pump.

The rotating action of the pump, therefore, results in a FLOW of hydraulic oil from the pump
which is dependent on the size of the gear teeth and the rotational speed of the pump shaft.
Resistance downstream due to hose size, adapter fittings, elbows and system valves will restrict
the flow from the pump, thus resulting in pressure. High pressure on the outlet side of the
housing forces the gears to deflect into the low pressure (inlet) side. The gear tips or teeth
contact the housing, preventing high pressure output oil from leaking back to the low pressure
side.

This contact between the gear teeth and the pump housing results in wear on the pump
housing and will produce cast iron contamination into the hydraulic system, especially with new
units. This inherent wear is normal and is expected but requires adherence to the maintenance
schedule, especially in regard to oil and filter changes after the initial break in period.

Following the break in period, housing wear due to loading of the gears will diminish and will
result in a steady state which can be maintained for an extended period. Introduction of
contaminants into the system or over-pressurization of the pump, however, will result in
excessive wear and eventually allow oil to leak back to the low pressure side of the pump.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 5 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 6 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Pump and Motor Repair Procedures: Disassembly
STEP 1 STEP 2

Place the pump in a vise with the drive shaft Mark each casting in the assembly with
pointing down. Clamp unit on the sides of machinists ink or a prick punch to orient the
the mounting flange. Do not clamp on the castings so unit can be reassembled later in
pilot diameter as it may damage the seating the proper position.
surface.

STEP 3 STEP 4.1

Loosen and remove the four cap screws and Remove the port end cover subassembly
washers with a socket and wrench. using steps 4.1 through 4.3:

4.1 Place the point of a large screw driver or a


chisel on the parting line between the port
end cover casting and the gear housing
casting. Gently tap to separate the casings
and port end.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 7 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
STEP 4.2 STEP 4.3

4.2 Place two large flat bladed screwdrivers 4.3 Lift off the port end cover
into the separation notches and pry up the subassembly.
port end cover until loose.

STEP 5.1 STEP 5.2

Remove the gear housing subassembly using 5.2 Lift off the gear housing sub-
steps 5.1 through 5.3: assembly.

5.1 Place the two large flat bladed


screwdrivers into the separation notches and
pry up the gear housing until loose.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 8 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
STEP 5.3 STEP 6

5.3 Remove the thrust plate from the Remove and discard the rubber section
housing. It may be necessary to gently tap seals from the top and the bottom gear
the thrust plate with the handle of a housing faces.
hammer or screw driver. Be careful not to
bend or score the thrust plate. Remove and
discard the small rubber pocket seals from
the thrust plate.

STEP 7 STEP 8

Wipe the gear face surface dry with a clean Remove the idler gear and the gear shaft.
lint free cloth. Mark the teeth of the gear set Keep them together as they are a matched
at their mesh point with machinists ink or set. Handle with care to avoid damage to
quick dry marker. This is to index the gear the journals, faces, and teeth.
set for proper orientation during
reassembly.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 9 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
STEP 9 STEP 10

Gently lift off the thrust plate. Be careful Inspect the bushings for wear. Replace
not to bend or score the plate and mating following the next steps if required.
surface of the casting. Remove and discard
the rubber pocket seals from the back of
the thrust plate. NOTE: Pay attention to
the orientation of the oil seal and channel
on the bottom of the thrust plate.

STEP 11 STEP 12

Use a bearing puller to remove the Use a large screw driver or a Check Tool to
bushings. remove the check valves.

Note: This step is optional depending on


the condition of the bushings.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 10 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
STEP 9 STEP 10

Inspect all the components for wear and Remove the channel seals and discard.
replace as required.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 11 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Failure Analysis
Large Particle Contamination
Particles too large to fit between the tight component tolerances of the gear pump or motor
will cause surface to surface contact removing material from the softer thrust plate. Damage to
the thrust plate surface, which provides a sealing surface between the high and low pressure
oil, leads to leaks and a loss of performance. Additionally, continued wear due to the
introduction of large contaminants results in additional contaminants, which perpetuates the
overall problem.

The pump thrust plate is one of the best places


to look for evidence contributing to the pump
failure. Score marks on the plate in the photo
indicate a trail of contaminants which were
dragged across the surface of the plate.

New components provide a smooth, even surface allowing a continuous oil film to exist
between the thrust plate and gear face. When these surfaces become scored the oil film
dissipates into the grooves interrupting the film. Metal to metal contact occurs, resulting in an
increase in friction and heat. The grooved plate surface can also provide an escape route for
high pressure oil to go back to the low pressure inlet, resulting in a loss of pumping efficiency.

Large contaminants lodged in the


spaces between the gear teeth will result in
scoring of the pump housing.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 12 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Large particle contamination may also result in
damage to the gear teeth.

Small Particle Contamination


Microscopic particles the size of airborne dust can accumulate in the tiny tolerances of the
hydraulic system. These particles can form a wedge between moving parts, increasing friction
and accelerating wear. The velocity of the tiny particles striking the wear surfaces can erode
material, weakening the wear surface and causing spalling. This erosion of metal leads to
internal leaks in critical components and adds additional contamination to the hydraulic
system. This wear reduces the system efficiency and affects pump or motor performance.

Smaller contamination particles will be


evident on the thrust plate in the form
of small score lines, and is most evident
at the pressure point of the gear mesh.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 13 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Contamination wear will also be present
on the bushing surface of the pump
drive shaft.

Small contaminants will produce minor


scoring of the shaft. Large particles may
produce severe wear and galling of the
shaft surface

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 14 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Cavitation
Excessive noise in a hydraulic system can be caused by the presence of air in the hydraulic oil.
Introduction of air into the system can be the result of a leak in the suction line, air bubbles
entrained in the oil, or insufficient pump or motor inlet flow which results in a vacuum. The
partial vacuum vaporizes some of the oil causing air and or water to come out of solution.

As the bubbles, created by cavitation and aeration, are carried around to the pump outlet, the
increase in pressure squeezes the bubbles. Implosions occur when the pressure becomes too
great and the bubbles collapse inward.

Air bubbles under pressure will implode and produce intense shock waves which bombard the
surface of the thrust plates. This process erodes the plates surfaces on the high pressure side.
This erosion reduces pump efficiency and results in increased wear due to loss of the hydraulic
film which normally protects from metal to metal contact.

Cavitation is shown on
the thrust plate on the
pressure outlet side of
the pump in the form
of pitting in the thrust
plate surface.

Discoloration of this
thrust plate may also
indicate that excessive
heat due to lack of oil
supply was also
present.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 15 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Excessive System Pressure
Pressure and hydraulic shock are also causes of pump failure. Pumps operating under a
continuous load at high pressure and for extended periods are susceptible to premature wear
and failure. In addition normal operation of tree cutting or heavy brush cutting can cause
sudden pressure spikes which may act on the system too fast for the pressure relief valves to
respond and protect the system from damage.

Forces generated by the pump outlet pressure and gear area causes a deflection of the gears.
This stresses the bushings that support the gear journals. The oil film needed to lubricate and
cushion the pump elements becomes thinner with the increase in pressure until direct contact
is made

System pressure in excess of the rated system pressure will affect the pump or motor either
over time if the excessive pressure is static, or immediately if the excessive pressure is
presented as a spike load.

Initially, damage resulting from excessive pressure will be displayed as cutouts exceeding
0.007 in depth inside the gear case housing. The system pressure deflects the gears into the
low pressure inlet side of the pump. If the system pressure increases above the pressure rating
of the pump, the gears deflect too far and the gear housing cut out becomes excessive.
Internal slip increases and the pump will become less efficient. The contaminant created by the
cut out can foul relief valves and other system components.

Gear cutout in Pump


Housing should not
exceed .007

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 16 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Excessive pressure and deflection of the gears in the pump housing will also result in the loss of
the lubricating film between the pump shafts and the bushings. Continued high pressure will
degrade the bushing and result in the bushing spinning in its housing.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 17 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Hydraulic shock loads to the hydraulic system normally result from excessive ground speed
while cutting heavy brush or trees and will be displayed as either cracks in the gear pump
housing or a broken drive shaft. Shock loads can cause an immediate component failure.
Sudden pressure spikes that exceed the pressure rating of the pump can crack the housing at
the port location and bolt hole areas of the casting, severely scoring the thrust plate surface,
and damage the drive shaft.

Sudden shock loads produced by sudden over-pressurization of the hydraulic system may cause
sudden failure of the pump drive shaft.

Transverse torsional shear


due to a high, single
overload application.

Torsional overload resulting


in transverse shear.

Smooth surface with swirl


pattern and barber poling
plastic deformation of the
shaft.

Over-pressurization of the hydraulic system could be the result of a slow acting or


malfunctioning main pressure relief valve, restrictions in the return to tank connection from the
motor, or malfunctioning motor and pump control components. Over-pressurization can also
occur from a failed quick disconnect fitting or a kinked hose.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 18 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Heat Damage
Heat is generated in a hydraulic system whenever oil dumps from an area of high pressure to
low pressure without doing mechanical work. Oil blowing over a relief valve, or flowing
through piping, bypassing a damaged o-ring, a valve, a clogged filter or strainer are all examples
of sources of heat. Proper reservoir size can dissipate much of the heat generated in a system.
On some applications an oil cooler must be added to sufficiently cool the oil. Other factors,
such as contamination, cavitation / aeration, improper oil viscosity can add to the heating
problems of a hydraulic system. In addition, excessive rotation speed of the pump due to high
input speed of the engine or power source can also create excessive heat.

Heat buildup causes the hydraulic oil to lose its viscosity, resulting in oil that no longer meets
specification. This greatly reduces the lubricating effects of the oil on the close tolerance parts.
The heated oil oxidizes, encouraging corrosion, leakage, and the development of sludge which
can clog filters and compound the heating problem.

Every 18F rise in oil temperature doubles the rate of corrosion on exposed surfaces

Excessive Heat:

Thins the system oil


Accelerates the breakdown of the oil
Promotes oxidation
Can be caused by worn components or excessive engine speed

With the loss of lubrication the thrust


plate becomes heated rapidly. The
plates become so hot that lead in the
alloy will be drawn out of the plate
and is smeared over the surface by
the rotating gears. The result is that
the entire plate will become
blackened.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 19 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
The excessive heat will also result in
severe damage to the nylon channel
seal and butyl rubber seal on the back
of the thrust plate thus propagating
further damage to the entire pump
and hydraulic system.

Exposure to excessive heat will also


discolor the ends of the gear teeth
near the gear face. The high heat
causes bluing of the teeth. With
continued operation the gear face and
thrust plate will start to weld
together. Friction generated from
continued operation could eventually
result in a seized pump.

Hydraulic oil temperature should be monitored continuously during operation of the mower to
prevent catastrophic failures due to high temperature operation.

Typical operating tolerances allow the system to operate at a temperature up to 100F over the
ambient temperature. On some applications an oil cooler must be added to sufficiently cool
the oil. If the system is operating with excessive temperatures, the unit should be shut down to
allow it to cool, and the source of overheating should be corrected prior to operating the unit.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 20 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Part Replacement Guidelines
If the Gear Set contains any of the following
defects, it should be replaced:

Wear on the hubs or in the seal areas


detectable by touch or in excess of .002.
Score marks, grooves, or burrs on the
outside diameter of the teeth.
Nicks, grooves, or fretting of the teeth
surfaces.
Wear or damage to the drive spline, key,
or keyway.

Wear in excess of .007 cut-out necessitates


replacement of gear housing. Place a straight-
edge across the bore. If you can slip a .007 feeler
gage in the cut-out area, replace the gear housing.

Where the cut-out is moderate, .005 or less, the


gear housing is still in good condition. If the
housing has equal size ports or no ports, the
housing may be flipped 180 (exchanging ports)
and reused.

If the gears are replaced, then the bushings must


be replaced also. Bushings should fit into the
bores with a light press fit.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 21 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Part Replacement Guidelines

Any scratches, grooves, erosions, or pitting on the


thrust plate face, the area that comes in contact
with the gear faces, necessitates the replacement
of the thrust plates.

Replace all rubber and polymer seals whenever


disassembling the pump. This includes the lip seal,
pocket seal strips, and section seals.

Always consult your factory Customer Support Representative before ordering replacement
parts. Often the cost of rebuilding a pump or motor exceeds the replacement costs of an
entire assembly. In this case the OEM supplier may not even offer a complete list of parts
due to their high costs as repair parts.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 22 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Drive Shaft
Alamo can use 1 of 2 types of driveline system to couple the pump to the front of the tractors
motor.

1. The most common use is a straight driveline with splines on both ends. There will be a
pulley adapter or hub with a splined coupler welded in place that is designed to fit the
specific tractor application. This is bolted to the tractors motor crankshaft pulley either
directly or with the aid of a machined pulley adapter. The straight driveline is inserted
into this adapter or hub and a free floating splined coupler connects opposite end of
the shaft to the input shaft of the pump.

2. The second type is a U-Joint type of telescoping driveline. This will attach to the pulley face
with a mounting flange and the pump end attaches to the pump by the means of a clamp yoke.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 23 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Common Drive Shaft Issues
Misalignment - This is a mode of failure associated only with the straight shaft (no U-Joint)
design. Typically this failure will result in excessive wear to all the splined areas of the shaft
assembly including the pump shaft, coupler and both ends of the drive shaft. Typical wear
results in a barrel shaped pump drive shaft such that the splines are worn down on each end.
Likewise, the internal splines of the coupler may be worn in a concave shape around the inside
diameter. Progression will result in the total loss of spline engagement and loss of power to the
pump. Other symptoms include pump shaft fatigue failures, fretting and pump bearing failures.
Alignment should be checked with a straight edge between the new pump shaft and the splines
of the crank shaft adapter without the shaft in the system. Likewise, vibration can be observed
by watching for high frequency movement of the shaft during operation.

Rotating Bending Fatigue as evidenced by beach marks around the circumference. Final
fracture is brittle, with a rough center region. (Shown bottom left)

Final failure is caused by cyclical loads or from misalignment.

Sporadic overpowering of the drive system will result in wear of the pump and coupler splines
in one direction as well as fretting corrosion on the pump shaft. This failure is attributable to
powering the mower into heavy brush or limbs rather than a slow controlled cutting operation.
(Shown bottom right)

Shaft failure comes from sporadic overload. This shaft also shows some rounding indicative of
misalignment.

Overpowering will also be indicated by wear on bushings in the crankshaft adapter or related
components.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 24 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Lack of lubrication of the drive shaft
Typical Shaft Failure due
components will result in wear to the to Lack of Lubrication
splines. High pressure grease or anti seize
compound must be applied to all
components during installation and replaced
at regular intervals throughout the life of
the machine.

The Drive shaft in the figure displays an


example of fretting corrosion. Fretting is a
condition that occurs between the drive
shaft and the drive coupling. These parts
are commonly lubricated with a heavy
grease/ anti-seize agent. Fretting damage
occurs when the grease picks up grit and the
small amplitude vibration associated with
the normal operation of the mower makes
the contaminated grease act like sand paper
and produces wear on the shaft.

As the wear progresses, the clearance between the parts becomes greater allowing more shaft
coupling movement. The wear accelerates until there is not enough engagement to carry the
torque load produced during mowing or tree trimming. As a result, the coupler will spin on the
shaft and the pump will stop working. To repair, the pump gear set, coupler and shaft will need
to be replaced.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 25 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Pump and Motor Repair Procedures Re-Assembly
STEP 1 STEP 2

Stone all machined casting surfaces with a Coat the outside diameter of the lip seal with
medium grit carborundum stone. If the Permatex Aviation Form-A-Gasket No.3 Non-
bushings were removed, deburr the bushing Hardening Sealant or equivalent.
bore using a deburring tool. Rinse all parts in a
solvent fluid. Air blast all parts and wipe them Be careful not to get Permatex on the inner lip
clean with a clean lint free cloth before starting of the seal as it will cause a lip seal failure.
the assembly.

STEP 3 STEP 4

Place the shaft end cover on an arbor press Apply Loctite No.262 to the threaded check
with the pilot facing up. Place the lip seal, with holes in the shaft end casting. Install the checks
the shoulder of the seal up, at the top of the in the shaft end cover using the check tool
seal bore. Press the lip seal into the shaft end
cover with a lip seal installation bar. The seal The checks must bottom out in the casting.
should be pressed in so it is flush with the
recessed face in the shaft end cover casting.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 26 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
STEP 5 STEP 6

Peen over the check holes in the shaft end If the shaft seal was removed from the shaft end
cover with a 1 steel ball and a hammer. This cover, It should be replaced at this time.
will insure that the checks do not back out of
the check holes during operation.

STEP 7 STEP 8

Install the bushings in the shaft end cover and Replace the channel seals in the groove
the port end cover. Use an arbor press to press provided on each thrust plate.
the bushings into the bottom of the bearing
bores.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 27 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
STEP 9 STEP 10

Locate the orientation mark on the gear Install the port end thrust plate onto the gear
housing and line it up with the mark on the set. Make sure the channel seals are properly
shaft end cover. Slide the gear housing over the oriented.
gear set. Make sure that the gear housing rests
tightly against the shaft end cover. Be careful
not to pinch the section seal. Squirt clean
hydraulic oil over the gear shaft and the idler
gear to provide initial lubrication when the
pump is started.

STEP 13 STEP 14

Pace the port end cover over the gear journals. Thread the four cap screws with the washers
The orientation mark on the port end cover into the shaft end cover and tighten them in a
must line up with the mark on the gear housing. cross corner pattern. Rotate the gear shaft of
Apply pressure to the casting with your hand or the pump with a 6 wrench to make certain here
tap lightly with a soft faced hammer until the is no binding in the pump.
port end cover rests tightly against the gear
housing.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 28 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
STEP 15 STEP 16

Pace the port end cover over the gear journals. Thread the four cap screws with the washers
into the shaft end cover and tighten them in a
The orientation mark on the port end cover must cross corner pattern. Rotate the gear shaft of
line up with the mark on the gear housing. Apply the pump with a 6 wrench to make certain
pressure to the casting with your hand or tap here is no binding in the pump.
lightly with a soft faced hammer until the port
end cover rests tightly against the gear housing.

STEP 17

After the cap screws are tightened and you are


sure there is no internal binding, tighten the cap
screws in a cross corner pattern to a final torque.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 29 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Lubrication and Oil Recommendations
All parts are lubricated by the hydraulic oil in the circuit. Particular
attention must be paid to keep the oil in the system clean. Whenever
there is a pump or motor failure and there is reason to suspect that
metal particles may be in the system, the oil must be drained, the
entire system flushed clean, and any filter screens thoroughly cleaned
or replaced. New oil should be supplied for the entire system. Only
suitable and recommended oil for use in circuits involving Alamo
supplied pumps and motors should be used.

Refer to the Recommended Lubricant Chart attached to the hydraulic


tank or refer to the units Operators Manual to determine the
required hydraulic oil.

Using good quality hydraulic oil conforming to the specifications listed


on the resources above is essential to satisfactory performance and
long life of the hydraulic system.

Use only filtered oil to fill the hydraulic system


to avoid contamination.

Oil used should conform to ISO 4406:99


standards for cleanliness and must meet a
minimum cleanliness of 18/16/14 before being
installed in the mower

All operators should be properly trained to


monitor the Return Filter Pressure Gauge
during Operation. The gauge at start up, or
when cold will indicate a reading in the red
portion of the gauge. After warm up, the
reading will fall to the green area if everything
is normal. If pressures stay in the red zone
after warm up, the filter should be replaced.

Oil should be changed on regular schedules in


accordance with the manufacturers
recommendations and the system should be
periodically flushed.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 30 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Recommended Test Procedure
If one section of a tandem pump is being tested, make sure that all other sections not being tested are
adequately supplied with oil. If any of the other sections run dry or if plugs are left in ports, serious and
permanent damage will result.

Use a suitable Pressure/Flow meter which incorporates a Pressure Gauge (6000psi), a Temperature
Gauge, Flow Meter and Flow Restriction Needle Valve.

Be sure there is an adequate supply of oil for the pump.

The oil should be good quality hydraulic oil rated at 150 SSU at 100 F with the oil temperature held at
120 F plus or minus 5 F (Test procedures are described in detail in SAE handbooks; see Hydraulic
Power Pump Test Procedure SAE J745c.)

Install the Pressure/Flow Meter in place of the Motor in the hydraulic Circuit.

Note: DO NOT INSTALL the Pressure/Flow meter in the line directly from the pump to the Brake Valve.
This line is NOT PROTECTED from over-pressurization by a Pressure Relief Valve. Hot oil must not be fed
into a cold pump. The pump could seize.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 31 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS
Operate the pump at least two minutes at zero pressure and at moderate speed (not over 1500
rpm). If pump becomes hot to touch, it is binding and could seize. This doesnt happen very
often, but if it does, pump will have to be disassembled and be rebuilt. Extra care should be
taken to remove burrs and to assure freedom from binding. Gradually increase the pressure on
a pump intermittently until the desired test pressure has been reached. This should take about
five minutes. Delivery should run close to the rated catalog performance figures which are
averaged from testing of several pumps. A 5% lower reading may be used as a rated minimum if
new or relatively new parts have been used. When rebuilding the pump with used parts from
the original pump, that is only those parts which appear to be satisfactory for re-use, a 10% or
15% lower reading is permitted depending on the performance expected from the equipment.
Ones own experience will prove the best guide here.

Pumps and motors used on Alamo Mowers are designed to operate with the tractors motor
speed at 1800 to 2150 RPM. Never exceed 2400 RPM at any time.

Check the mowers Operators Manual or Service Manual for specific specifications. In general,
a good pump will maintain 75-80% of its rated flow up to relief pressure.

Hydraulic Gear Pump and Motor Failure Analysis and Repair Guide Page 32 of 32
Alamo Industrial | 1502 E Walnut St, Seguin, TX 78155 | www.alamo-industrial.com | 800-882-5762 92016GS

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